GEOMETRICAL PARAMETERS BASED OPTIMIZATION OF HEAT TRANSFER RATE IN DOUBLE PIPE HEAT EXCHANGER USING TAGUCHI METHOD D.
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1 ISSN IJESR/March 2018/ Vol-8/Issue-3/18-24 D. Bahar et. al., / International Journal of Engineering & Science Research GEOMETRICAL PARAMETERS BASED OPTIMIZATION OF HEAT TRANSFER RATE IN DOUBLE PIPE HEAT EXCHANGER USING TAGUCHI METHOD D. Bahar* 1, Jakirahemed MD 2, K. Srikanth 3, S. Rajesham 4 1 Assistant Professor, Department of Mechanical Engineering, RGUKT-Basar, Nirmal, Telangana, India. 2 Assistant Professor, Department of Mechanical Engineering, RGUKT-Basar, Nirmal, Telangana, India. 3 Assistant Professor, Department of Chemical Engineering, RGUKT-Basar, Nirmal, Telangana, India. ABSTRACT 4 Professor, Department of Mechanical Engineering, RGUKT-Basar, Nirmal, Telangana, India. In recent years, because of increasing demand by industries for heat exchangers that are more efficient, compact, and cost effective, heat transfer augmentation has gained great momentum. Therefore, researchers are focusing the development of heat exchangers which are highly efficient, compact, and cost effective. In the present study, a double pipe heat exchanger is designed and analyzed by passing hot water in the inner pipe and cold water in the annulus (between inner pipe and outer pipe) in counter flow configuration. There are various process and geometrical factors that affect the heat transfer characteristics of the heat exchanger. In this paper, heat transfer from hot water to cold water in double pipe concentric tube heat exchanger is analysed and optimised on the basis of geometrical factors: inner pipe diameter, outer pipe diameter and tube thickness. Four different models (with different geometrical factors) are designed in CATIA V5 and CFD analysis is carried out in ANSYS. The UALITEK-4 software is used for Taguchi analysis. Taguchi analysis shows that which combination of geometrical factors and levels gives the optimum heat transfer rate. Results obtained from Taguchi analysis shows that inner tube and outer tube diameter should be larger and tube thickness should be smaller for optimum heat transfer rate. Tube thickness is found to have significant effect on heat transfer rate. Keywords: Heat exchanger, double pipe heat exchanger, Taguchi method, Counter flow, ANSYS WORKBENCH, UALITEK INTRODUCTION A heat exchanger is a device that transfers thermal energy from a high temperature fluid to a low-temperature fluid with both fluids moving through the device (Eckert and drake 1987). The heat transfer rate depends on the conductivity of the dividing wall and convective heat transfer coefficient between the wall and fluids. Heat transfer occurs by three principles: conduction, convection and radiation. Radiation effects are generally factored in the heat transfer coefficients (Holman 2002). Conduction takes place when the heat from the high temperature fluid flows through the surrounding solid wall. The conductive heat transfer can be maximised by selecting a minimum thickness of wall of a highly conductive material. The major contribution in heat transfer takes place through convection (Kadari and Elumagandla 2016). Rennie (2004) studied the heat transfer characteristics for a double pipe helical heat exchanger for both counter and parallel flow with both the boundary conditions of constant heat flux and constant wall temperature. From the study, it was found that the outer pipe had a major contribution on the overall heat transfer coefficient. So, it was concluded that during the design of a double pipe helical heat exchanger, the outer pipe plays an important role to get a better overall heat transfer coefficient. Jung and Assanis (2006) concluded in their numerical work that a predictive heat exchanger model is suggested for the investigation of the effect of the geometric changes due to the nonlinear characteristics of the heat exchanger performance related to geometric changes. *Corresponding Author 18
2 Zhou (2014) optimized the design of heat exchanger and observed that the overall heat transfer coefficient increases with increase in diameter. In the present work, a double pipe heat exchanger is designed and analyzed by passing hot water in the inner pipe and cold water in the annulus (between inner pipe and outer pipe) in counter flow configuration. There are three main types of heat exchangers: a. The Recuperative type in which the flowing fluids exchanging heat are on either side of a dividing wall. b. The Regenerative type in which the hot and cold fluids pass alternately through a space containing a matrix of material that provides alternately a sink and a source for heat flow. c. The Evaporative type in which a liquid is cooled continuously by evaporation in the same space as the coolant. Recuperative type of heat exchanger is further classified into three types on the basis of relative direction of hot and cold fluid: a. Parallel flow type when both the fluids move in parallel in the same direction. b. Counter flow type when the fluids move in parallel but in opposite directions. c. Cross flow type when the directions of flow are mutually perpendicular The counter flow heat exchanger is more effective than parallel flow for the given surface area. Hence a counter flow heat exchanger is taken into consideration for the present study. A model of double pipe heat exchanger considered in this research work is shown in Fig 1, in which portion of heat exchanger between section A-A and B-B is considered for analysis. Figure 1 also shows the temperature variation of cold fluid and hot fluid along with direction of flow. 2. OBJECTIVES Fig. 1: Double Pipe Heat Exchanger I. To design the concentric tube double pipe heat exchanger with different combination of geometrical factors (inner tube diameter, outer tube diameter and tube thickness) and analyze the temperature distribution in the fluids (hot water and cold water). II. To find out the combination of geometrical factors to optimize the heat transfer rate (between hot water and cold water) in double pipe heat exchanger. Copyright 2018 Published by IJESR. All rights reserved 19
3 3. DEFINITION AND MODELLING OF THE PROBLEM 3.1 Design Of Experiments The word experiment is used in a quite precise sense to mean an investigation where the system under study is under the control of the investigator. This means that experiment is the process in which purposeful changes are made to the input variables of systems so that one may observe and identify the reasons for changes that may be observed in the output response. To investigate or discovers something about any process there are number of experiments required to find response of desired output. Therefore, to reduce the number of Experiments and to obtain good quality of investigation the term named Design of experiments (DOE) is highly useful. Taguchi's approach to design of experiments (DOE) is easy to be adopted and applied for users with limited knowledge of statistics; hence it has gained a wide popularity in the engineering and scientific community. 3.2 Taguchi's Method Taguchi's techniques have been used widely in engineering design. The Taguchi method contains system design, parameter design, and tolerance design procedures to achieve a robust process and result for the best product quality. The main trust of Taguchi's techniques is the use of parameter design, which is an engineering method for product or process design that focuses on determining the parameter (factor) settings producing the best levels of a quality characteristic (performance measure) with minimum variation. Taguchi designs provide a powerful and efficient method for designing processes that operate consistently and optimally over a variety of conditions. Taguchi specified three situations: Larger the better (for example, agricultural yield). Smaller the better (for example, carbon dioxide emissions). On-target, minimum-variation (for example, a mating part in an assembly). The taguchi method is applied in four steps: 1) Pick out the quality characteristics and design parameters important to the Product/process. 2) Design and conduct the experiments. 3) Analyze the results to determine the optimum conditions. 4) Run a confirmatory test using the optimum conditions. 3.3 Mathematical Modeling: Orthogonal Arrays (Oas) Experiments The effect of many different parameters on the performance characteristic in a process can be examined by using the orthogonal array experimental design proposed by Taguchi. Once the parameters affecting a process that can be controlled have been determined, the levels at which these parameters should be varied must be determined. Determining what levels of a variable to test requires an in-depth understanding of the process, including the minimum, maximum, and current value of the parameter. If the difference between the minimum and maximum value of a parameter is large, the values being tested can be further apart or more values can be tested. If the range of a parameter is small, then less value can be tested or the values tested can be closer together. 3.4 Selection Of Suitable Geometrical Parameters The double pipe heat exchanger would normally be used for many continuous systems having small to medium duties and accordingly size can be smaller to larger. In the present work length of inner pipe as well as outer pipe in heat exchangers is kept constant as1000 mm and two levels of factors (inner, outer tube diameter and tube thickness) are taken in to consideration as shown in Table1. : Inner diameter of inner pipe : Inner diameter of outer pipe t : Thickness of pipes (same for inner as well as outer pipe) Copyright 2018 Published by IJESR. All rights reserved 20
4 Table1: Factors of Dimensions by Taguchi Method (length of the tubes L =1000mm) Levels/Factors Di (mm) Do (mm) t (mm) Level Level A full factorial design requires 2^3 experiments as opposed to the four which are needed for the Taguchi version of the experiment using L4 orthogonal arrays shown in Table 2 Table 2: Dimensions Of Models (length L = 1000 mm) Models (mm) (mm) t (mm) Heat Exchanger 1 Heat Exchanger 2 Heat Exchanger 3 Heat Exchanger Modelling and CFD Analysis of Heat Exchangers As mentioned before portion between sections A-A and section B-B (Fig. 1) is considered for analysis. Designed solid model, cross sectional view and side view are shown in Fig. 2a, 2b and 2c respectively Fig. 2a: Solid Model of DPHE Fig. 2b: Cross sectional Fig. 2c: Side view of DPHE Geometrical parameters mentioned in Table 2, are incorporated in this designed model and consequently four heat exchangers are modeled. After modeling these heat exchangers are imported in to ANSYS, in which after fine meshing of these models common input is fed to these models shown in Table 3 and temperature contours in inner tube and outer tube for heat exchangers 1,2,3, and 4 are shown in figure 3a, 3b, 3c and 3d respectively. From the fluent database liquid and solid are considered as water and copper respectively. Table 3: Common boundary conditions for models in ANSYS Boundary Condition type Mass-flow rate ( kg/s ) Temperature ( K ) Direction Specification Hot inlet Mass-flow inlet Normal to boundary Hot outlet Pressure outlet Cold inlet Mass-flow inlet Normal to boundary Cold outlet Pressure outlet Copyright 2018 Published by IJESR. All rights reserved 21
5 Fig. 3a: Temperature contours in Heat exchanger 1 Fig. 3b: Temperature contours in Heat exchanger 2 Fig. 1c: Temperature contours in Heat exchanger 3 Fig. 3d: Temperature contours in Heat exchanger 1 From Figure 3a, 3b, 3c and 3d it can be seen that contours in the inner pipe (hot fluid is flowing) has high temperature and contours in the outer pipe (cold fluid is flowing) has low temperature. Along the length of the pipe also temperature is varying in inner as well as outer pipe. At the outlet of inner and outer pipe, temperatures of hot and cold fluid are found which are tabulated in Table 4. Temperature difference of hot fluid and cold fluid is also computed in Table 4. Table 4: Outlet temperatures and temperature difference of hot and cold fluid Heat Exchangers (H.E) Inlet Temperatures (K) Outlet Temperatures (K) Temperature difference Cold fluid Hot fluid Cold fluid Hot fluid Cold fluid Hot fluid H.E H.E H.E H.E By taking the temperature components from Table 4 and using the following equations 1, 2 & 3, Average heat transfer rate of hot fluid and cold fluid is calculated for all the models. Results are shown in Table 5. c = m& C DT...(1) pc c h = ṁ C ph T h...(2) h +c avg =...(3) 2 Where; c = heat transfer rate in cold fluid, h = heat transfer rate in hot fluid, avg = average heat transfer rate D Tc = Temperature difference in cold fluid D Th = Temperature difference in hot fluid Copyright 2018 Published by IJESR. All rights reserved 22
6 Table 5: Average heat transfer rate in models (HE) (mm) (mm) t(mm) avg ( kw) HE HE HE HE RESULTS Figure 4 shows the outcome of UALITEK-4 results, in which heat transfer rate is varying with respect to levels of the parameters. Form the graph following observations are inferred. 1) As changes from level 1 (10mm) to level 2 (15mm), Heat transfer rate increases. As diameter increases surface area will also increases which results in to enhancement of heat transfer rate by convection. 2) As changes from level 1 (21mm) to level 2 (26mm), Heat transfer rate increases by convection. 3) As tube thickness changes from level 1 (0.25mm) to level 2 (0.75mm), Heat transfer rate decreases. Since increment in tube thickness will reduce the heat transfer rate by conduction. Fig. 4: Average effect of geometrical parameters on heat transfer rate From above mentioned findings it can be deduced that for maximum heat transfer rate, inner and outer tube should be larger and tube thickness should be smaller. The same can be validated from Table 6. Table 6: Optimum conditions and performance Copyright 2018 Published by IJESR. All rights reserved 23
7 From Table 6, it can be concluded that for optimal heat transfer rate, best combination of parameters will be level 2,2&1 for inner tube diameter ( ), outer tube diameter ( ) & tube thickness (t) respectively and it is also indicated that Average performance of the heat exchanger will be kw and optimum performance will be kw. Optimal value can be validated from Table 4, in which theoretically calculated average heat transfer rate for combination 2,2&1 (H.E 3) is around kw. 5.1 Analysis Of Variance (ANOVA) The main aim of Analysis of variance (ANOVA) is to enquire the design parameters and to indicate which parameters are significantly affecting the output parameters. In the analysis, the sum of squares and variance are calculated. F-test value at 95 % confidence level is used to decide the significant factors affecting the process and percentage contribution is calculated. Table 7: Demonstration of the analysis of variance for factors Analysis of Variance (ANOVA) S. No. Factors DOF Sums of Variance F-Ratio Pure Sum Percent squares 1 In Tub Dia Out Tub Dia Thickness Other Error Total % From Table 7 it is evident that dominant factor is tube thickness and effect of outer and inner tube diameter is insignificant. it can be observed that its contribution will be around %. Second factor is inner tube diameter and its contribution will be around %. Last factor is outer tube diameter having contribution only %. 6. CONCLUSION From the results it is conspicuous that average heat transfer rate in heat exchanger increasing with increasing inner diameter of inner tube and outer tube. Results also shows that heat transfer rate in heat exchanger also increases by decreasing tube thickness. Therefore for optimum performance of double pipe heat exchanger, thickness should be smaller and inner and outer tube diameter should be larger. From the results it is also revealed that effect of tube thickness as compared to inner diameter of inner tube and outer tube is much significant. REFERENCES [1] Eckert ERG, Drake RM. Analysis of heat and mass transfer. Hemisphere Publ., Washington, DC, USA, [2] Holman JP. Heat transfer, 9 th ed., McGraw Hill, New York, NY, USA, 2002; [3] Kadari D, Elumagandla S. Design and fabrication of concentric tube heat exchanger. International Journal of latest trends in Engineering and Technology 2006; 7(3). [4] Rennie TJ et. al., Numerical and Experimental Studies of a Doublepipe Helical Heat Exchanger, Department of Bioresource Engineering McGill University, Montreal, August [5] Jung D, Assanis DN. Numerical modeling of cross flow compact heat exchanger with louvered fins using thermal resistance concept. SAE Paper, [6] Zhou Z, Wang J, Liu Y, Liang J. Design Optimization Of Tube-In-Tube Helical Heat Exchanger Used In JT Refrigerator. International Cryocooler Conference, Inc., Boulder, Copyright 2018 Published by IJESR. All rights reserved 24
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